Powder sintering device

ABSTRACT

A powder sintering device is disclosed. The powder sintering device includes a support unit, an actuator unit located on the support unit, a sintering unit, and a reaction unit. The reaction unit is located inside of the sintering unit and heated by the sintering unit. The reaction unit is fixed to the actuator unit and driven to rotate by the actuator unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims all benefits accruing under 35 U.S.C. §119 from China Patent Application No. 201410678790.9, filed on Nov. 24, 2014 in the State Intellectual Property Office of China, the content of which is hereby incorporated by reference. This application is a continuation under 35 U.S.C. §120 of international patent application PCT/CN2014/095750 filed on Dec. 31, 2014, the content of which is also hereby incorporated by reference.

FIELD

The present disclosure relates to powder sintering devices, particularly, to a rotating powder sintering device.

BACKGROUND

Sintering is one important process in the preparation of inorganic materials. Sintering methods can be divided into two main types: static sintering and dynamic sintering. Dynamic sintering involves sintering a variety of materials while mixing the variety of materials to produce an accurate local chemical stoichiometry of the variety of materials, and avoid a heterogeneous formation. A rotary furnace is used for dynamic sintering. However, dynamic sealing of the rotary furnace is poor, and the rotary furnace cannot effectively seal any gas leakage. Thus, the sintering of sulfur and phosphorus would produce toxic gases.

SUMMARY

One aspect of the present disclosure is to provide a powder sintering device.

The powder sintering device comprises a support unit, an actuator unit located on the support unit, a sintering unit, and a reaction unit located inside the sintering unit and heated by the sintering unit. The reaction unit is fixed to the actuator unit and driven by the actuator unit to rotate.

A method using the powder sintering device is also provided. The method comprises: providing and mixing materials to be reacted; loading the materials to be reacted into the reaction unit; fixing the reaction unit inside the sintering unit, and sintering while rotating the sintering unit; unloading the reaction unit; replacing the gas in the reaction unit; and obtaining a composite material.

The powder sintering device provided in this disclosure and used in the method for preparing the composite material is rotated during the sintering process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of one embodiment of a powder sintering device.

FIG. 2 is a cross-sectional view of another embodiment of the powder sintering device.

FIG. 3 shows charge and discharge curves of a sulfur cathode composite material prepared by the powder sintering device in FIG. 1.

DETAILED DESCRIPTION

It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure.

Referring to the FIG. 1, one embodiment of a powder sintering device 10 is disclosed. The powder sintering device 10 includes a support unit 11, an actuator unit 12, a sintering unit 13, and a reaction unit 14. The actuator unit 12 is located on the support unit 11. The reaction unit 14 is located inside of the sintering unit 13.

The support unit 11 includes a first horizontal beam 110, a second horizontal beam 111, a first vertical beam 112, a second vertical beam 113, a third vertical beam 114, a first bearing 115, and a second bearing 116. The first horizontal beam 110 is supported by the first vertical beam 112 and the second vertical beam 113. The second horizontal beam 111 is supported by the first vertical beam 112 and the third vertical beam 114. The first bearing 115 is located on top end of the first vertical beam 112 via a first bearing seat 117. The second bearing 116 is located on top end of the second vertical beam 113 via a second bearing seat 107.

The actuator unit 12 includes a motor 120, a decelerator 121, a conveyer belt 122, a chain wheel 123, a first rotation shaft 124, and a second rotation shaft 125. The motor 120 and the decelerator 121 are located on the second horizontal beam 111. The decelerator 121 is connected to the motor 120. The first rotation shaft 124 and the second rotation shaft 125 are opposite to and spaced from each other. The chain wheel 123 is located on the first rotation shaft 124. One end of the conveyer belt 122 is located on the decelerator 121, another end of the conveyer belt 122 is located on the chain wheel 123. Thus, the decelerator 121 can decrease the rotation speed of spindle of the motor 120. The conveyer belt 122 can drive the chain wheel 123 rotating. Thus, the chain wheel 123 can drive the first rotation shaft 124 to rotate, and the rotation speed of the first rotation shaft 124 is less than the rotation speed of the motor 120. In one embodiment, a rotation speed of the first rotation shaft 124 can be in a range greater than 0 round/minute and less than 10 round/minute. The first rotation shaft 124 and the second rotation shaft 125 are separately located on the first bearing 115 and the second bearing 116. The first rotation shaft 124 is supported by the first bearing 115. The second rotation shaft 125 is supported by the second bearing 116.

The sintering unit 13 includes a furnace body 130, a heating element 131, and a thermocouple 132. The furnace body 130 is supported by the first horizontal beam 110. The heating element 131 and the thermocouple 132 are located inside of the furnace body 130. The furnace body 130 includes a first or an upper wall 1301, a second or a lower wall 1302, and four side walls 1303. A reaction chamber 134 is defined by the upper wall 1301, the lower wall 1302 and the four side walls 1303. The lower wall 1302 is located on the first horizontal beam 110 of the support unit 11. Two heating elements 131 are separately located inside the upper wall 1301 and the lower wall 1302. The thermocouple 132 is located inside the upper wall 1301, and extended into the reaction chamber 134. A temperature in the reaction chamber 134 can be measured by the thermocouple 132. A control device can control the heating to the furnace body 130 depending on the temperature in the reaction chamber 134. Two opposite side walls 1303 separately define two opposite holes (not shown). The first rotation shaft 124 and the second rotation shaft 125 are extended into the reaction chamber 134 through the two opposite holes, and spaced from each other a distance. A furnace door (not shown) is located on one of the four side walls 1303.

The heating mode of the heating element 131 may be a muffle furnace heating, infrared heating, microwave heating, etc. A temperature of the sintering unit 13 can be in a range from about 0° C. to about 700° C.

The reaction unit 14 includes a sintering tank 141 and a shield 142. The sintering tank 141 is located in the shield 142. The reaction unit 14 is located between the first rotation shaft 124 and the second rotation shaft 125, and fixed to the first rotation shaft 124 and the second rotation shaft 125 by means of welding, bolting or other mechanical fastening ways. The reaction unit 14 rotates as the first rotation shaft 124 rotates. A shape of the sintering tank 141 can be a regular geometric shape, includes column, ball, square, and other geometrical shape combination. In one embodiment, the sintering tank 141 is a square shaped container. During heating, a loading quantity of materials in the sintering tank 141 is 80% or less of the volume of the sintered tank 141. It is to be understood that the shield 142 is optional.

Referring to the FIG. 2, a powder sintering device 20 of another embodiment is disclosed. The powder sintering device 20 includes a support unit 11, an actuator unit 12, a sintering unit 13, and a reaction unit 24. The actuator unit 12 is located on the support unit 11. The reaction unit 24 is located inside of the sintering unit 13. The support unit 11, the actuator unit 12, the sintering unit 13 in FIG. 2 are same as the support unit 11, the actuator unit 12, the sintering unit 13 in FIG. 1. The reaction unit 24 in FIG. 1 has a structure different with the reaction unit 14 in FIG. 1.

The reaction unit 24 includes a sintering tube 241 and a flange plate 242. The sintering tube 241 includes a closed end and an open end. The closed end is fixed to an end of the first rotation shaft 124 by means of welding, bolting or other mechanical fastening ways. The open end is fixed to the flange plate 242 by means of welding, bolting or other mechanical fastening ways. The flange plate 242 is fixed to an end of the second rotation shaft 125 by means of welding, bolting or other mechanical fastening ways. That is, the sintering tube 241 is fixed between the first rotation shaft 124 and the second rotation shaft 125. As the first rotation shaft 124 rotates, the reaction unit 24 also rotates with the first rotation shaft 124. During heating, loading quantity of materials in the sintering tube 241 is 80% or less of the volume of sintering tube 241. It is to be understood that a cover located on one side of the sintering unit 13 can be opened to put the sintering tube 241 in or out.

A method for preparing composite material by the powder sintering device provided in this disclosure is provided, and the method includes:

-   -   (1) providing and mixing materials to be reacted;     -   (2) loading the materials to be reacted into the reaction unit,         fixing the reaction unit inside the sintering unit, and         sintering while rotating the sintering unit; and     -   (3) unloading the reaction unit, replacing the gas in the         reaction unit, and obtaining the composite material.

An example of a method for preparing a sulfur cathode composite material via the powder sintering device 10 is provided.

In step (1), 508.5 g of sulfur powder, 169.5 g of polyacrylonitrile, and 25.425 of diphenylguanidine are weighed and added into a V shape mixer to mix about 2 hours. After 2 hours mixing, the mixture in the V shape mixer is removed to form the materials to be reacted.

In step (2), the materials to be reacted are loaded into the sintering tank 141. The volume of the materials loaded to be reacted accounts for one half of the volume of the sintered tank body 141. The sintering tank 141 is sealed and fixed in the shield 142 to form the reaction unit 14. The reaction unit 14 is put into the reaction chamber 134 through the furnace door. The reaction unit 14 is fixed between the first rotation shaft 124 and the second rotation shaft 125. The reaction unit 14 is rotated by the first rotation shaft 124 and sintered during the rotation. The sintering teperature can be in a range from about 200° C. to about 700° C. The sintering time depends on the materials to be reacted. The sintering teperature can be in a range from about 200° C. to about 400° C. In one embodiment, the sintering time is 3 hours, and the sintering temperature is 400° C. After sintering, the reaction unit 14 is naturally cooled with the furnace body 130. Then, the furnace door is opened after the reaction unit 14 is naturally cooled, the reaction unit 14 is detached from the first rotation shaft 124 and the second rotation shaft 125, and the sintering tank body 141 is taken out of the shield 142.

In step (3), residual gas in the sintering tank 141 is replaced by a ventilation device or a vacuum device to obtain a sulfur cathode composite material. In one embodiment, the residual gas in the sintering tank body 141 is evacuated by a vacuum pump in a ventilated kitchen. After the replacing of the residual gas, the sulfur cathode composite material is taken out of the sintering tank body 141. Charge and discharge curves of the sulfur cathode composite material are shown in FIG. 3.

The powder sintering device provided in this disclosure and used in the method for preparing the composite material is rotated during the sintering process. The reaction unit in the powder sintering device provides dynamic sealing to prevent gas leakage during the sintering process. In addition, the sintering process to solve the material sublimation issue and liquid deposition issue to ensure that the components of material can react in accordance with designed stoichiometric ratio, to enhance the purity of the product.

Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the embodiments being indicated by the following claims. 

What is claimed is:
 1. A powder sintering device, comprising: a support unit; an actuator unit located on the support unit; a sintering unit; a reaction unit located inside the sintering unit and heated by the sintering unit, the reaction unit being fixed to the actuator unit and driven by the actuator unit to rotate.
 2. The powder sintering device of claim 1, wherein the support unit comprises a first horizontal beam, a second horizontal beam, a first vertical beam, a second vertical beam, a third vertical beam, a first bearing, and a second bearing; the first horizontal beam is supported by the first vertical beam and the second vertical beam; the second horizontal beam is supported by the first vertical beam and the third vertical beam; and the first bearing and the second bearing are separately located on the first vertical beam and the second vertical beam.
 3. The powder sintering device of claim 2, wherein the actuator unit comprises a motor, a decelerator, a conveyer belt, a chain wheel, a first rotation shaft, and a second rotation shaft; the motor and the decelerator are located on the second horizontal beam; the first rotation shaft and the second rotation shaft are opposite to and spaced with each other; the chain wheel is located on the first rotation shaft; one end of the conveyer belt is located on the decelerator, another end of the conveyer belt is located on the chain wheel; and the first rotation shaft and the second rotation shaft are separately located on the first bearing and the second bearing.
 4. The powder sintering device of claim 3, wherein the sintering unit comprises: a furnace body defining a reaction chamber, the furnace body is supported by the first horizontal beam, the first rotation shaft and the second rotation shaft are embedded into the reaction chamber, and spaced with each other in a distance; and a heating element and a thermocouple located inside of the furnace body.
 5. The powder sintering device of claim 4, wherein the furnace body comprises a first wall, a second wall, and four side walls; the reaction chamber is defined by the first wall, the second wall, and the four side walls; and the second wall is located on the first horizontal beam.
 6. The powder sintering device of claim 4, wherein the reaction unit is located between the first rotation shaft and the second rotation shaft, and fixed to the first rotation shaft and the second rotation shaft.
 7. The powder sintering device of claim 6, wherein the reaction unit comprises a sintering tank and a shield, and the sintering tank is located in the shield.
 8. The powder sintering device of claim 6, wherein the reaction unit comprises a sintering tube and a flange plate, the sintering tube comprises a closed end and an open end, the closed end is fixed to the first rotation shaft, the open end is fixed to the flange plate, and the flange plate is fixed to the second rotation shaft.
 9. The powder sintering device of claim 3, wherein a rotation speed of the first rotation shaft is less than 10 revolutions/minute.
 10. A powder sintering method, comprising: providing a powder sintering device, the powder sintering device comprising: a support unit; an actuator unit located on the support unit; a sintering unit; a reaction unit located inside of the sintering unit and heated by the sintering unit, the reaction unit being fixed to the actuator unit and rotating by the actuator unit; providing and mixing materials to be reacted; loading the materials to be reacted into the reaction unit, fixing the reaction unit inside the sintering unit, and sintering while rotating the sintering unit; unloading the reaction unit, replacing the gas in the reaction unit, and obtaining a composite material.
 11. The powder sintering method of claim 10, wherein the replacing the gas in the reaction unit is performed by a ventilation device or a vacuum device. 